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Name: ____________

University of Hartford
College of Engineering, Technology, and Architecture
Department of Mechanical Engineering

ME 480-Modern Manufacturing Processes Test 2 Fall 2017

Figure 1 ISO Insert Nomenclature

Figure shows the nomenclature for a turning tool holders and inserts.
A. What is the length of the insert edge indicated for the tool holder indicated in the figure 1?

12 mm

B. Describe the rake angle of the insert indicated in figure 1?

Can not say much

C. What fields in the insert nomenclature and the tool holder nomenclature must match?

2. Figure shows a 100 mm dia end mill with eight teeth machining a 125 mm wide × 500 mm
long ×30 mm thick slab. The mill is symmetrically located on the block as shown. The cutter is
set to an axial depth of cut, 𝑎𝑝 set at 15 mm and the feed per tooth of 0.5 mm per revolution
while cutter rotates at 360 RPM

100

A. Which side is exit point of the cutter?

i) A ii) B

B. Determine the entry and exit angle of the cutter.

50
cos 𝜙𝑠 = → 𝜙𝑠 = cos −1 0.8 → 𝜙𝑠 = 36.9°;
62.5
50
cos(180 − 𝜙𝑒 ) = → 𝜙𝑒 = 180 − cos −1 0.8 → 𝜙𝑒 = 180 − 36.9 = 143.1°
62.5

C. average chip thickness

𝑓 cos 𝜎(cos 𝜙𝑠 − cos 𝜙𝑒 ) 0.5 × cos 0 × (cos 36.9 − cos 143.1)


𝑡𝑚 = = 𝜋 = 0.4314 𝑚𝑚
𝜙𝑒 − 𝜙𝑠 (143.1 − 36.9)
180

D. feed velocity in mm per minute

𝑣𝑓 = 𝑓𝑛𝑁 = 0.5 × 8 × 360 = 1,440 𝑚𝑚/𝑚𝑖𝑛


E) material removal rate in 𝑚𝑚3 /𝑚𝑖𝑛

𝑚𝑚3
𝑄 = 𝑎𝑒 𝑎𝑝 𝑣𝑓 = 100 × 0.5 × 1,440 = 72,000 = 72𝑐𝑚3 /𝑚𝑖𝑛
𝑚𝑖𝑛

F) power required for the milling operation in specific cutting energy of the material is given as
3,000 𝑁/𝑚𝑚3

𝑚𝑚
𝑃 = 𝑢𝑄 = 3,000 × 72,000 = 𝑁 = 3,600𝑊 = 2.6𝑘𝑊
𝑚𝑖𝑛

3. A surface grinding operation is performed with a 10 in  × 0.5 in wide grinding wheel at


2,500 RPM. Draw a diagram to show a down grinding operation when the work is reciprocates at
a velocity of 50 ft per minute. The grinding depth (infeed) is 0.008 in and a cross feed of 0.125 in
on a 12 in long × 4 in wide ×2 in thick block.

A) What is the rate of material removal?

𝑄𝑤 = 𝑎𝑒 𝑎𝑝 𝑣𝑓 = 0.125 × 0.008 × 50 × 12 = 0.6 𝑖𝑛3 /𝑚𝑖𝑛

B) What is the specific material removal rate (per unit width of grinding)?

𝑄𝑤 0.6 𝑖𝑛3
𝑄′𝑤 = = = 4.8 /𝑖𝑛
𝑎𝑒 0.125 𝑚𝑖𝑛

C) What is the velocity ratio factor, q in the operation?

𝑖𝑛
𝑉𝑠 = 𝜋𝐷𝑁 = 𝜋 × 10 × 2,500 = 78,450 = 6,545 𝑓𝑝𝑚
𝑚𝑖𝑛

𝑉𝑠 2,356.2
𝑞= = = 157.1
𝑉𝑤 15

D) Is this velocity ratio, q, an acceptable one?

i) Yes ii) thermally unfavorable, No


E) Estimate the Service Life factor, G if the diameter of the wheel is measured as 9.96 in after
grinding the surface.

𝑄𝑤 12 × 4 × 0.008
𝐺= =𝜋 = 1.22
𝑄𝑠 (102 − 9.962 )0.5
4

F) Determine the grain depth of cut if the aspect ratio is 8 and the density of abrasive particles on
the grinding wheel is 2,000 grains /in2

1 1
4 𝑉𝑤 𝑎𝑝 2 √ 4 15 0.008 2
𝑡𝑚 = √ ( ) = × ( ) = 0.00038 𝑚𝑚
𝐶𝑟 𝑉𝑠 𝐷𝑒 2,000 × 8 2,356.2 10

G) power required for grinding if the specific cutting energy is given as 3,000 N/𝑚𝑚2

N
3,000 = 435 𝑘𝑠𝑖
𝑚𝑚2
𝑖𝑛 𝑖𝑛
𝑃 = 𝑢𝑄 = 435,000 × 0.6 𝑙𝑏 = 261,000𝑙𝑏 = 0.66 ℎ𝑝
𝑚𝑖𝑛 𝑚𝑖𝑛